Inflatable cushioning device

ABSTRACT

An inflatable cushioning device is provided that is comprised of three layers of flexible gas-impermeable material. One of such layers of material is formed with spaced protrusions throughout its length and width. This layer, when sealed to a flat layer of similar shape along its periphery and at various locations between the protrusions, forms an inflatable assembly. The ends or tips of the spaced protrusions are connected to another flat layer of similar size and shape for structural support. When inflated the protrusions act as the main structure for supporting a load upon the inflatable device. The protrusions are spaced close enough to provide ample load support but far enough apart to minimize the overall volume of air needed to inflate the device to full size.

BACKGROUND

[0001] 1. Field of the Invention

[0002] The invention relates to an inflatable cushioning device and morespecifically to an inflatable cushioning device that is versatile enoughto be used as a mattress, seat cushion, or package cushioning material.

[0003] 2. Discussion of the Prior Art

[0004] Cellular devices are documented extensively in the prior art.Cellular noninflatable devices have been used extensively as packagingand cushioning material. Such devices are represented in the prior artgenerally by patents U.S. Pat. No. 3,231,454 to Williams, Jan. 26, 1966,3294387 to Chavannes, Dec. 5, 1966, U.S. Pat. No. 3,865,679 to Hale,Feb. 11, 1975, 4533583 to May, Aug. 6, 1985, and U.S. Pat. No. 5,030,501to Colvin, et al., Jul. 9, 1991. These devices, while using a cellularpattern for structural support and cushioning, generally are notinflatable, not refillable, nor reusable. Also, they are not designed tominimize the volume of gases or liquids needed to fill them to fullsize. In addition, they are specific to the packaging industry.

[0005] Air cushions and air mattresses are another category of cellulardevices. These are generally represented in the prior art by patentsU.S. Pat. No. 2,318,492 to Johnson, May 4, 1943, U.S. Pat. No. 2,575,764to Morner, Nov. 20, 1951, U.S. Pat. No. 2,731,652 to Bishop, Jan. 24,1956, and U.S. Pat. No. 4,662,012 to Torbet, May 5, 1987. Again, whileinventive, these devices are either not inflatable or they are notdesigned to minimize the volume of gases or liquids needed to fill themto full size.

[0006] Inflatable beds and cushions used for hospital patient care areone more category of cellular devices. These inflatable structures useair cells to distribute a patient's weight and prevent the developmentof bedsores. These structures fulfill a need but are highly specializedto their field of use. U.S. Pat. No. 4,422,194 to Viesturs, et al., Dec.27, 1983, and U.S. Pat. No. 5,640,731 to Toedter, Jun. 24, 1997 discloseinventive use of air cells but are highly complicated and are notreadily adaptable to be used outside of the patient care industry. Thesetypes of cellular devices are suitable for medical purposes where thevolume of air used and the cost of manufacturing are of little concern.Patent U.S. Pat. No. 4,982,466 to Higgins, et al., Jan. 8, 1991 isbroader in its declared use. However, it uses a complicated air fillmechanism and is not designed to minimize the volume of air needed tofill it to full size.

[0007] Of all the cellular devices in the prior art none are at onceinflatable, easy and economical to manufacture, versatile enough to beused in multiple applications such as cushions, mattresses, or packagingmaterial, and designed to reduce the volume of air needed for filling tofull size.

OBJECTS AND ADVANTAGES

[0008] The primary advantage of the inflatable cushioning device is thatit uses significantly less volume of air to fill to full size than othersimilar sized inflatable devices. This advantage is particularlyapplicable to portable inflatable devices such as camping mattresses orcushions where it is undesirable to manually blow large volumes of airor carry an air pump for inflation.

[0009] A second advantage of the inflatable cushioning device is itsversatility. It can be sized and shaped to fit nearly any inflatableapplication.

[0010] A third advantage of the inflatable cushioning device is that ithas no complicated moving parts, no tubes or hoses to interconnect theair cells, and requires no pump.

[0011] A fourth advantage of the inflatable cushioning device is that,unlike typical packaging materials, it is inflatable and reusable thusreducing waste disposal costs. Also, because it is inflatable thepresent invention can form-fit around package contents that requireprotective cushioning.

[0012] More objects and advantages of the inflatable cushioning devicewill become apparent or be pointed out in the drawings and ensuingdescription

SUMMARY

[0013] The inflatable cushioning device is constructed of three layersof flexible gas-impermeable material. Two of the layers are sealedtogether along their periphery forming an inflatable assembly. One ofthese two layers is flat and the other is formed with spacedprotrusions. The spaced protrusions extend away from the flat layer. Toprevent the inflatable assembly from ballooning out from the center wheninflated, the two layers that comprise the inflatable assembly aresealed together at various locations between the spaced protrusions.These seal locations also form a manifold area for air to flow to andfrom the spaced protrusions during inflation and deflation. An inflationand deflation port is provided in the inflatable assembly. A third layerof similarly sized material is sealed to the tips of the spacedprotrusions. This layer provides lateral stability to the spacedprotrusions.

[0014] In the inflatable cushioning device, when the protrusions areefficiently spaced, the volume of air required to fill it issignificantly less than the volume displaced by the entire object. Inother words an inflatable device, such as a mattress, with a similarheight, width, and length without the spaced protrusions would require alarger volume of air to fill to full size. This makes the inflatablecushioning device ideal to be used in portable applications such as acamping mattress, seat cushion, or other accessory where it is notdesirable to carry along an awkward or heavy air pump or to fill theportable device with one's own breath.

DESCRIPTION OF THE DRAWINGS

[0015]FIG. 1 is an isometric view of the inflatable cushioning device.

[0016]FIG. 1A is an exploded isometric view of the three layers thatcomprise the inflatable cushioning device.

[0017]FIG. 2 is an isometric view of the inflatable assembly.

[0018]FIG. 3 is a cutaway isometric view of the inflatable cushioningdevice.

[0019]FIG. 4 is an isometric view of a conventional air mattress.

[0020]FIG. 5 is an isometric view of a second embodiment of theinflatable cushioning device.

[0021]FIG. 6 is an isometric view of the inflatable assembly of thesecond embodiment.

[0022]FIG. 7 is a cutaway isometric view of the second embodiment.

[0023]FIG. 8 is an isometric view of a third embodiment of theinflatable cushioning device.

[0024]FIG. 9 is a cutaway isometric view of the third embodiment.

DETAILED DESCRIPTION OF THE INVENTION Description of the PreferredEmbodiment

[0025] Referring to FIG. 1, an inflatable cushioning device is depicted.The device is comprised of three layers of flexible gas-impermeablematerial. The three layers can be seen individually in the exploded viewof FIG. 1A. FIG. 1A depicts flat layer 20 on top. Protrusion layer 22 isin the middle. Protrusion layer 22 is formed with spaced protrusions 50that appear as cylindrical structures. Stabilizing layer 24 is on thebottom. Referring back to FIG. 1, flat layer 20 on top is sealed toprotrusion layer 22 that is in the middle. The tips of spacedprotrusions 50 are secured to stabilizing layer 24 that is on thebottom. Referring to FIG. 1 in more detail, flat layer 20 and protrusionlayer 22 are sealed at their respective peripheries, hereafter referredto as periphery seal 40. Flat layer 20 and protrusion layer 22 are alsosealed together at various locations between spaced protrusions 50,hereafter referred to as manifold seals 44.

[0026] Referring to FIG. 2, sealing flat layer 20 and protrusion layer22 along periphery seal 40 and manifold seals 44 forms an inflatableassembly 30. An inflation and deflation port 70 is provided for theattachment of a device such as a tube or valve (not shown).

[0027]FIG. 3 is a cutaway isometric view of the device. The manifoldseals 44 in the cutaway are depicted as interior junctions between flatlayer 20 and protrusion layer 22. The manifold seals 44 maintain thestructural integrity of the inflatable assembly and form manifold area60 through which air is distributed to spaced protrusions 50. Also seenin the cutaway portion of FIG. 3 are spaced protrusions 50 that are influid communication with each other through manifold area 60.

[0028] Also shown in FIG. 3 is stabilizing layer 24. Stabilizing layer24 is sealed to the inflatable assembly 30 at the tips of spacedprotrusions 50. The sealed locations, hereafter referred to as tip seals42, occur at the junctions between the tips of spaced protrusions 50 andstabilizing layer 24.

Operation of the Preferred Embodiment

[0029] When inflated, the spaced protrusions 50 support a load placed onthe inflatable cushioning device in FIG. 1. Spaced protrusions 50 arelaterally stabilized by stabilizing layer 24 and thus do not deflect outof their vertical orientation. The distance between spaced protrusions50 is such that the volume of air needed to fill the invention issignificantly less than any inflatable device of the same size in theprior art. This novelty will become more apparent by comparing FIG. 4with FIG. 1. FIG. 4 represents a conventional inflatable mattress havingthe same dimensions as the device in FIG. 1 but without spacedprotrusions 50. In order to inflate the mattress in FIG. 4, one mustfill its entire volume with air. This volume of air is significantlygreater than the volume needed to fill the inflatable cushioning devicein FIG. 1. Considering the inflatable cushioning device in FIG. 1, in anembodiment where spaced protrusions 50 are cylindrical and regularlyspaced at a distance equal to their diameter, the volume of air requiredto fill it to full size could be as little as one-fifth the volumeneeded to fill the mattress shown in FIG. 4.

Description of a Second Embodiment

[0030]FIG. 5 is an isometric view of a second embodiment of theinflatable cushioning device. This embodiment is comprised of fourlayers of flexible gas-impermeable material. Two protrusion layers 22are sealed together along a periphery seal 40.

[0031] The spaced protrusions 50 in FIG. 5 appear as cylindricalstructures extending away from a common central plane. One stabilizinglayer 24 is secured to the tips of spaced protrusions 50 on top of thestructure and another stabilizing layer 24 is similarly secured to thebottom.

[0032] Referring to FIG. 6, sealing the two protrusion layers 22together and providing an inflation and deflation port 70 produces theinflatable assembly of the second embodiment 32.

[0033]FIG. 7 is a cutaway isometric view of the second embodiment. Thecutaway reveals manifold seals 44 as well as the manifold area 60 in thecenter of the inflatable cushioning device. All spaced protrusions 50 ofthis embodiment are in fluid communication with each other throughmanifold area 60. Also shown in FIG. 7 are stabilizing layers 24 on thetop and bottom of the structure. The stabilizing layers 24 are securedto the tips of spaced protrusions 50 by tip seals 42.

Operation of the Second Embodiment

[0034] The operation of the second embodiment is the same as thepreferred embodiment. The same air-minimizing property is realized.

Description of a Third Embodiment

[0035]FIG. 8 is an isometric view of a third embodiment of theinflatable cushioning device. In this embodiment there are twoinflatable assemblies 30. As can be seen in FIG. 8, lateralstabilization of the spaced protrusions 50 is accomplished by sealingthe two inflatable assemblies 30 together at the tips of theirrespective spaced protrusions 50. Inflation and deflation ports 70 areprovided in both inflatable assemblies 30.

[0036]FIG. 9 is a cutaway isometric view of the third embodiment.Tip-to-tip seals 46 connect the inflatable assemblies 30. The tip-to-tipseals 46 occur where the spaced protrusions 50 of each inflatableassembly 30 meet. Manifold seals 44 perform the same function here as inthe preferred embodiment. In the cutaway portion it can be seen thatspaced protrusions 50 of both inflatable assemblies 30 are in fluidcommunication through their respective manifold areas 60. However, theinflatable assemblies 30 are not in fluid communication with each other.In other words the two inflatable assemblies 30 are separatelyinflatable.

Operation of the Third Embodiment

[0037] Operation of the third embodiment is the same as the preferredembodiment except that there are two inflatable assemblies 30. In thecase that one inflatable assembly is ruptured the other can stillsupport a load on the inflatable cushioning device. The sameair-minimizing property is realized as in the preferred embodiment.

Conclusion and Scope

[0038] From the preceding description the reader will understand thatthe inflatable cushioning device is simple, versatile, reusable, andmost importantly it significantly reduces the volume of air needed tofill it to full size.

[0039] In the preceding description it is recognized that the words“sealed” and “secured” are meant to represent any method known in thefield of joining flexible gasPage impermeable material such as a bondingagent, weld, ultrasonic seal, heat seal, or the like. It is alsorecognized that the spaced protrusions 50 could be of any shape orlength as long as the spaced protrusions 50 support a load on thestructure and are spaced to minimize the amount of air needed to fillthe structure. It is further recognized that the protrusion layer 22could be formed by any known means of forming protrusions or cells inflexible gas-impermeable material. It is still further recognized thatstabilizing layer 24 need not be gas-impermeable in order to completethe structure. The stabilizing layer 24 could also be sealed along itsperiphery to the inflatable assembly 30 without changing the essence ofthe invention. These modifications and others that do not depart fromthe spirit and scope of the invention will be apparent to those skilledin the art. Thus, the scope of the invention is not to be limited by thespecification and is rather to be determined by the appended claims.

List of reference numerals

[0040]20—flat layer

[0041]22—protrusion layer

[0042]24—stabilizing layer

[0043]30—inflatable assembly

[0044]32—inflatable assembly of the second embodiment

[0045]40—periphery seal

[0046]42—tip seal

[0047]44—manifold seal

[0048]46—tip-to-tip seal

[0049]50—spaced protrusion

[0050]60—manifold area

[0051]70—inflation and deflation port

What is claimed is:
 1. An inflatable cushioning device comprising: alayer of flexible gas impermeable material containing a plurality ofspaced protrusions, a flat layer of gas impermeable material of similarsize and shape sealed to said layer at its periphery and at variouslocations between said spaced protrusions to form an inflatableassembly, wherein said spaced protrusions extend away from said flatlayer and said spaced protrusions are in fluid communication with eachother, a port for inflation and deflation in said inflatable assemblyfor the attachment of an inflationary means, and an additional flatlayer of similar size and shape connected to the tips of all said spacedprotrusions of said inflatable assembly, whereby said spaced protrusionsare laterally stabilized by their connection to said additional flatlayer, are spaced to minimize the volume of air needed to fill saidinflatable assembly, and support a load on the structure when inflated.2. An inflatable cushioning device comprising: two layers of gasimpermeable material each containing a plurality of spaced protrusions,said two layers sealed to each other at their peripheries and at variouslocations between said spaced protrusions to form an inflatableassembly, wherein said spaced protrusions extend away from a commoncentral plane and are in fluid communication with each other, a port forinflation and deflation in said inflatable assembly for the attachmentof an inflationary means, and two flat layers of similar size and shapeconnected to the tips of all said spaced protrusions on each side ofsaid inflatable assembly, whereby said spaced protrusions are laterallystabilized by their connection to said two flat layers, are spaced tominimize the volume of air needed to fill said inflatable assembly, andsupport a load on the structure when inflated.
 3. An inflatablecushioning device comprising: a layer of gas impermeable materialcontaining a plurality of spaced protrusions, a flat layer of gasimpermeable material of similar size and shape sealed to said layer atits periphery and at various locations between said spaced protrusionsto form a first inflatable assembly, wherein said spaced protrusionsextend away from said flat layer and are in fluid communication witheach other, a similarly formed second inflatable assembly with similarspaced protrusions, wherein the tips of said similar spaced protrusionsare connected to the tips of said spaced protrusions of said firstinflatable assembly, and a port for inflation and deflation in saidfirst inflatable assembly and said second inflatable assembly for theattachment of an inflationary means, whereby said spaced protrusions andsaid similar spaced protrusions are laterally stabilized by theirconnection to each other, are spaced to minimize the volume of airneeded to fill said first inflatable assembly and said second inflatableassembly, and support a load on the structure when inflated.